Wood Imitating Facade Element and Procedure for Making the Same

ABSTRACT

The invention relates to a façade element which is suitable to mount on the outside ( 3 ) of a building ( 2 ). According to the invention plate shaped façade elements ( 5, 5   1  . . . ) consisting of glass fibre reinforced plastics, and which exhibit a wooden structure ( 6, 6   1  . . . ) on its outwards ( 7 ) turnable side ( 8, 8   1  . . . ) and which externally have the shape of standing and/or lying panels ( 9, 9   1  . . . ), are arranged to be mounted next to one another and attached to the wall ( 10 ) in question, to form a façade facing for the building ( 2 ) in question. The invention also relates to a procedure for manufacturing of the façade elements ( 5, 5   1  . . . ).

The present invention relates to a façade element adapted to be used on the outside of a building, whereby plate shaped façade elements, consisting of glass fibre reinforced plastics, and externally having the shape of standing and/or lying panels and being arranged, mounted next to one another and attached to the wall in question, to form a façade facing for the building in question, are arranged with an edge portion which permits overlapping mounting thereof and attached to a wall next to one another laterally and/or in vertical direction, whereby the edge region of the façade element plate exhibits a channel shaped reception portion for receiving the edge portion of connectable adjacent façade element plate, and that the reception portion is formed by a tunnel shaped edge end portion of one edge portion of the façade element plate.

The façades of buildings are exposed to effects of weather and wind, and finally it is not sufficient to treat the surface of the façade with paint, glazing or any other protective agent, but it will then be necessary to renew the destroyed façade board for board. This is a measure which demands a great deal of work and which is expensive.

It is also desirable to be able to change the style of buildings, for example buildings provided with plates containing asbestos and/or which no longer are so beautiful, and which need either to be changed or painted.

By SE 300 683 B a facing panel for façades is previously known, which may consist of anything from plastics to metal. Said known panel portion (5) exhibits an edge portion (7) which is bent upwards, while the adjacent panel portion exhibits an edge portion which is bent inwards, and an additional flange (6). The edge portion (7) which is bent upwards is received between the edge portion which is bent inwards and the flange (6).

The known facing panels (1, 5) are first attached by means of adhesive stripes (3) and then further by means of nails or screws, etc. (4) before the next panel is applied. The edge of the known panel plate (5) is held in place on the panel plate (1) attached to the façade only by means of the additional flange (6) arranged on the underside of the respective panel plate (5).

This is a considerable drawback as far as use, production and mounting of the façade elements in question are concerned.

The main object of the present invention is, thus, to achieve a façade element which, among other things, solves the problems described above simply, efficiently and also in a favourable way as far as the costs are concerned. It should be possible to use the façade element for the construction of new buildings as well as for the renovation of old buildings.

Said object is achieved by means of a façade element according to the present invention, which is mainly characterized in that one edge portion of a façade element plate, which has a wooden structure on its outwards turnable side, exhibits a straight shape, whereby said plate shaped façade elements are arranged to be attached to the wall of a building in that they are screwed and/or nailed to mounted bolts with overlapping of said façade element plate at least along one edge side.

According to the present invention the edge portion of an adjacent façade element plate is held in place by means of one edge portion of the entire longitudinal tunnel shaped edge end part, and may be attached to the support together, i.e. both edge portions of adjacent mounted façade element plates can be attached by means of common fastening means.

A further object of the invention is to achieve a procedure for manufacturing of façade elements adapted for the outside of a building according to the invention.

Said further object is achieved by means of a procedure according to the invention, which is mainly characterized in that, in a mould forming the intended size of the façade element, a release agent is applied, that a layer of gel coat, which exhibits the surface structure of the intended façade element, is applied in the mould for setting, whereupon a number of glass fibre mats with polyester plastic are put into the mould, that a gel coat having a thickness of at least 1 mm is applied, and that glass fibre mats having a thickness of between 3 and 5 mm are put into the mould.

Thus, the invention makes it possible to obtain plate shaped façade elements for buildings, and which are simple to manufacture as well as to handle, and also to mount in a safe and efficient way.

The invention is described in the following in the form of a number of preferred embodiments with reference to the accompanying drawings, in which

FIG. 1 shows a façade element according to the invention seen from its outside and obliquely from above,

FIG. 2 shows the façade element from its opposite side,

FIG. 3 shows a further example of a façade element seen from its outside,

FIG. 4 shows said façade element from it opposite side,

FIG. 5-6 show example of still a further façade element from its outside and inside, respectively,

FIG. 7, finally, shows example of façade elements which are coupled together,

FIG. 8 is a schematic view of the mounting of façade elements on the outside of a building,

FIG. 9 is a view of a joint between façade element plates which are put together and coupled together,

FIG. 10 is a schematic view of a corner joint at the corners of a building between façade element plates which are put at an angle,

FIG. 11 shows a portion of a window opening with joint between the window and enclosing façade element plates,

FIG. 12-20 show examples of further façade element plates and their construction and function, whereby

FIG. 12 shows a façade element plate seen obliquely from above with a variant of fastening means and coupling means,

FIG. 13 shows a bolt with a façade element plate attached thereto,

FIG. 14 shows façade element plates in pairs which are coupled together with each other and attached to a bolt,

FIG. 15 shows in detail, seen from the side, the coupling between the façade element plates,

FIG. 16 is a perspective view obliquely from above of a narrow façade element plate provided with fastening and coupling organs along the long sides,

FIG. 17 shows the façade element plate illustrated in FIG. 16 from behind,

FIG. 18 shows the façade element plates illustrated in FIGS. 16-17 in pairs obliquely from above in coupled together condition,

FIG. 19 shows the façade element plate illustrated in FIG. 18 from behind, and

FIG. 20 shows how such façade element plates can be adjusted and coupled together laterally.

A façade 1 for the outside 3 of a building 2, which is formed by several plate shaped façade elements 5, 5 ¹ . . . of plastic material being laterally 4 coupled together, consists of glass fibre reinforced plastics. More precisely, said façade element plates 5, 5 ¹ . . . exhibit wooden structure 6, 6 ¹ on its in direction outwards 7 turnable side 8, 8 ¹. On the same outwards turned side 8, 8 ¹ . . . the façade element plates 5, 5 ¹ . . . have the shape of standing and/or lying panels 9, 9 ¹ . . . and are, mounted next to one another and attached to the wall 10 in question, arranged to form a façade facing on the building 2 in question.

Said façade element plates 5, 5 ¹ . . . are provided with an edge portion 11, 12, which makes possible an overlapping mounting of façade element plates 5, 5 ¹ . . . next to each other with hidden joints 13. Thus, next to each other laterally 4 and/or vertically 14 relative to the wall in question mounted and attached façade element plates 5, 5 ¹ . . . form a façade facing for the building 2 in question. Thanks to the wooden structure on its front and the front formed as boards, said façade 1 is felt as a real wooden façade. Said façade facing is formed by glass fibre reinforced panel plates of plastics with a surface of gel coat, and which have a structure which is not much different from painted wood, so that it has the same wooden structure with veins and knots. It is very well suited as an outer panel on buildings as small houses, as it is intended to replace existing wooden panel and other façade covering when restoring and new construction. It requires very little maintenance, as it does not get mouldy or flakes as painted wooden panel does. It is also possible to mount it on the outside of existing wooden panel or to completely replace such after removing it. Joints 13 between façade element plates 5, 5 ¹ . . . are obtained thanks to the fact that an edge region 15 of the façade element plate 5 exhibits a channel shaped reception portion 16 for receiving suitable edge portion 17 of adjacent connectable façade element plate 5 ¹, and said reception portion 16 is formed by a tunnel shaped edge end portion of at least one edge portion 18 of the façade element plate 5. Thus, at least one edge portion 17 of a façade element plate 5 exhibits straight shape or its shape is adapted to said reception portion 16 of an overlapping connectable façade element plate 5 ¹, for example as is illustrated in FIG. 1 and in FIG. 7, or elements 19, 20 respectively, adapted to cover corners 21 of a façade and/or a joint 22 along windows 23, are formed by edge plates 26, 27 with adapted shape, which may be filled with an insulating material 24, 25, as straight mouldings and/or mouldings put at an angle of plastic material, which also may have a wooden structure on their outside.

Said façade element plates 5, 5 ¹ . . . are mounted on the wall as a suggestion by means of acid proof stainless screws 28 or by means of nails. The support is the same as for wooden panel, for example 28×70 bolts 29 with 600 cc. Finished holes 30 may be arranged at suitable places for the screws in the plates 5, 5 ¹.

The procedure for manufacturing façade element plates 5, 5 ¹ . . . intended for the outside 3 of a building 2, according the above description, is that in a mould forming the size of the façade element plate to be made a release agent is applied. Then a layer of gel coat exhibiting the surface structure of the intended façade element plate is applied in the mould for setting, whereupon a number of glass fibre mats with polyester plastic are put into the mould. Suitably gel coat having a thickness of at least 1 mm and glass fibre mats having a thickness of between 3 and 5 mm are put into the mould.

The use of façade element plates 5, 5 ¹ . . . intended for the outside 3 of a building 2 according to the above description is carried out in that plate shaped façade element plates 5, 5 ¹ . . . are attached to the wall 10 of the building by attaching said plates on mounted bolts 29 by means of screws 28 and/or nails whereby said façade elements 5, 5 ¹ are overlapping each other at least along one edge side 17, 18. Said façade element plats 5, 5 ¹ . . . consisting of glass fibre reinforced plastics with an outside 8, 8 ¹ . . . having a wooden structure, and which may be painted in an optional colour, may for example have the following dimensions: Thickness 3-5 mm. Length up to about 10 m. Width up to about 2 m.

Said façade element plates may be in the form of mouldings with a length of several meters to be cut, for example by means of a cutting wheel.

FIGS. 12-20 show embodiments of façade element plates 105, 105 ¹; 205, 205 ¹ according to alternative embodiments, which differ from the plates 5, 5 ¹ described above and shown in FIGS. 1-11 by their fastening element 150 and 250, respectively, and holding elements 151 and 251, respectively.

According to the embodiment shown in FIGS. 12-15 the plates 105, 105 ¹ are wide, while the plates 205, 205 ¹ according to the embodiment shown in FIGS. 16-20 are narrow, but the principle is the same for both.

A façade covering comprises such façade element plates 105, 105 ¹; 205, 205 ¹ and is intended for the outside of a building. Such plate shaped façade element plates, which consist of glass fibre reinforced plastics and which externally have the shape of standing and/or lying panel, are arranged, mounted next to each other and attached to the wall in question, to form the façade covering for the building in question. The façade element plates 105, 105 ¹; 205, 205 ¹ are provided with a straight edge portion 117 and 217, respectively, which makes it possible to mount them with overlapping and attach them to the wall next to each other laterally and/or in vertical direction. Opposite edge regions of respective façade element plate exhibit a channel shaped reception portion 150 and 250, respectively, for receiving a straight edge portion 117 ¹, 217 ¹ of connectable adjacent façade element plate. The reception portion 150; 250 is formed by a tunnel shaped edge end portion of one edge portion of the façade element plate, and has one edge portion of a façade element plate, which exhibits a wooden structure on its outwards turnable side, arranged to exhibit a straight shape and is arranged to have such a width B that said straight portion 117 ¹, 217 ¹ of connectable façade element plate 105 ¹, 205 ¹ may be received therein. Said plate shaped façade elements are arranged to be attached to the wall of a building in that they are attached to mounted bolts by means of screws and/or nails, whereby said façade elements are overlapping each other at least along one edge side.

Said straight edge portion 117; 217 of a façade element plate 105; 105 ¹; 205, 205 ¹ extends along a common longitudinal centre plane 175; 275, whereby the façade element plate extends up to the edge region of the opposite channel shaped edge end portion 175; 275 shaped as a tunnel of the reception portion 150; 250 of the façade element plate in question.

Thereby, an element 151; 251, which is displaced from the longitudinal centre plane 175; 275 of the façade element plate in question in the depth direction of the element, and which is connected or connectable to said façade element plate, forms as well a fastening element for said façade element plate 105; 205, together with the edge side 118; 218 of the reception portion 150; 250, as also a holding element in the cross direction 300 for adjacent laterally mountable façade element plate 105 ¹, 205 ¹.

The holding element 151; 251 is formed by a plate, which is fastened to the inside of one lateral edge portion of the respective façade element plate, or which is integrated with said façade element plate, and said plate, which preferably is glued to the inside of said façade element plate or attached thereto in any other way, may be arranged to extend along the whole edge side 118; 218 of said façade element plate 105; 205.

Said combined fastening element 151; 251 and holding element 151; 251 is/are located opposite to a tunnel shaped edge end portion 150; 250 of one edge portion 118; 218 of the associated façade element plate.

Said element 151; 251 preferably consists of the same material as the façade element plates 105, 105 ¹; 205, 205 ¹. Said element 151; 251 projects from the façade element plate by a distance C, which is smaller than or equal to the internal width D of said tunnel shaped edge end portion.

Said façade element plates are attached to the bolts 182 on the wall by means of screws and/or nails, which are received in preferably pre-made holes 181; 281 in the plates.

Said combined fastening element and holding element 151; 251 are received internally on the façade element plate with such a portion 400; 500 that a slot shaped cavity 180; 280 is formed behind the façade element plate up to the opposite straight end edge portion of the façade element plate.

The nature and the function of the invention should have been clear from the above description.

Of course, the invention is not limited to the embodiments described above and illustrated in the accompanying drawings. Modifications are possible, especially as to the constitution of the different parts, or by using similar technique, without departing from the scope of the invention, as it is defined in the patent claims. 

1.-10. (canceled)
 11. A facade element for a wall of a building, the facade element having a plate shape and of a glass-fiber reinforced plastic material, and plural facade elements mounted adjacent to each other and attached to the wall form a panel, the facade element comprising: an edge portion configured for overlapping mounting of the facade element to an adjacent facade element, wherein the edge portion includes a channel-shaped reception portion configured to receive an edge portion of the adjacent facade element, and the reception portion is a tunnel-shaped edge end portion of the edge portion, wherein the edge portion of a facade element having a wooden structure on an outward side has a straight shape configured to attach the facade element to the wall by fasteners; and the edge portion having the straight shape extends along a longitudinal center plane of the facade element, whereby the facade element extends up to an edge of the opposite tunnel-shaped edge end portion of the facade element; and an element displaced from the longitudinal center plane in a depth direction and connected to the facade element, the element configured as a fastening element for the facade element and as a holding element for the adjacent facade element.
 12. The facade element of claim 11, wherein the fastening element is located opposite the tunnel-shaped edge end portion of one edge of the facade element.
 13. The facade element of claim 12, wherein the fastening element projects from the facade element by a distance that is less than or equal to an internal width of the tunnel-shaped edge end portion.
 14. The facade element of claim 11, wherein the fastening element is received internally on the facade element thereby forming a slot-shaped cavity behind the facade element up to the opposite end edge portion of the facade element.
 15. The facade element of claim 11, wherein the fastening element is the same material as the facade element.
 16. The facade element of claim 11, wherein the holding element is a plate that either is attached to the inside of one side edge portion of respective facade element or is integrated with the facade element.
 17. The facade element of claim 16, wherein the plate extends along a whole side edge portion of the facade element.
 18. The facade element of claim 16, wherein the fastening element is located opposite the tunnel-shaped edge end portion of one edge of the facade element.
 19. The facade element of claim 18, wherein the fastening element projects from the facade element by a distance that is less than or equal to an internal width of the tunnel-shaped edge end portion.
 20. The facade element of claim 16, wherein the fastening element is received internally on the facade element thereby forming a slot-shaped cavity behind the facade element up to the opposite end edge portion of the facade element.
 21. The facade element of claim 16, wherein the fastening element is the same material as the facade element. 